Ring and Pinion

This procedure covers the removal and replacement of the ring and pinion gears in the front or rear differential of a 2023 Rivian EDV 500 electric delivery van.

Warnings

Tools required

Parts

• Ring and pinion gear set (matched) × 1 — Use OEM specification for correct ratio
• Pinion bearing kit (inner and outer bearings, races, crush sleeve) × 1 — Use OEM specification
• Pinion seal × 1 — Use OEM specification
• Side bearing set × 1 — Use OEM specification
• Ring gear bolts × 1 — Use OEM specification - one-time use bolts
• Differential cover gasket or RTV sealant × 1 — Use OEM specification
• Gear marking compound × 1 — Prussian blue or equivalent

Fluids

• 75W-90 GL-5 Gear Oil — 2 qt

Preparation

1. Disconnect 12V auxiliary battery negative terminal and follow Rivian HV system lockout procedures per service manual
2. Raise vehicle on lift or use jack stands rated for commercial vehicle weight, ensuring vehicle is secure
3. Remove wheels from axle being serviced (front or rear)
4. Remove brake calipers and secure out of the way without hanging on brake hoses
5. Mark driveshaft orientation to differential yoke and remove driveshaft
6. Place drain pan under differential and remove differential cover, draining gear oil completely
7. Clean differential housing interior and inspect for metal shavings or damage indicating additional component failure
8. Photograph or mark carrier bearing cap orientation and side for reassembly reference

Procedure

1. 1

   Remove differential carrier assembly
   Remove carrier bearing cap bolts and mark the caps left and right for proper reassembly. Use differential spreader tool carefully (no more than 0.010" spread) to separate carrier housing. Remove carrier assembly with side bearings attached. Keep side bearing shims organized by side if present.
2. 2

   Remove ring gear from carrier
   Remove ring gear bolts from carrier. Note that these are typically one-time use bolts. If ring gear is tight, use soft drift punch on alternating bosses to separate. Clean carrier and ring gear mating surfaces thoroughly.
3. 3

   Remove pinion gear assembly
   Mark pinion nut position relative to pinion shaft for reference. Hold pinion yoke and remove pinion nut (this will destroy crush sleeve - replacement required). Use bearing puller to remove yoke from pinion shaft. Drive pinion shaft rearward out of housing, catching inner bearing. Remove pinion oil seal. Remove outer pinion bearing race and inner bearing race from housing using bearing race puller.
4. 4

   Measure and record original pinion depth
   Before removing old pinion, use pinion depth gauge tool to measure existing pinion depth setting. Record this measurement and note any shim thickness behind inner pinion bearing race. Check new pinion gear for variance number etched on pinion (typically +/- number in thousandths of inch). This variance must be factored into pinion depth calculation.
5. 5

   Install new pinion bearing races
   Clean bearing race bores in differential housing. Using bearing race driver or press, install new outer pinion bearing race into housing. Install appropriate shim(s) based on pinion variance number and original measurements, then install inner pinion bearing race. Races must be fully seated with no gaps.
6. 6

   Set pinion depth
   Install inner pinion bearing onto new pinion shaft using press. Install pinion into housing with outer bearing in place. Use pinion depth gauge tool to verify pinion depth setting matches calculated specification based on pinion variance marking. Adjust shims behind inner race as necessary to achieve correct depth. This is critical for proper gear contact pattern.
7. 7

   Set pinion bearing preload
   Install new crush sleeve onto pinion shaft. Install outer bearing, pinion seal (lubricated with gear oil), and yoke. Install new pinion nut. While holding yoke, tighten pinion nut gradually, checking rotating torque frequently with inch-pound torque wrench. Target preload is typically 15-25 in-lbs for new bearings. Once crush sleeve is compressed, preload cannot be reduced - only increased. Do not over-tighten. If preload is exceeded, entire crush sleeve and pinion nut must be replaced and process repeated.
8. 8

   Install ring gear on carrier
   Clean ring gear and carrier mating surfaces with solvent and ensure completely dry. Install new ring gear onto carrier, aligning bolt holes. Install new ring gear bolts and tighten in star pattern to proper specification (refer to service manual - typically 90-100 ft-lbs for this application but verify). Apply threadlocker if specified by manufacturer.
9. 9

   Install side bearings
   If side bearings were removed from carrier, press new side bearings onto carrier. Ensure bearings are fully seated against carrier shoulder. Install original shims if present, or prepare to set side bearing preload during installation.
10. 10

    Install carrier assembly and set backlash
    Install carrier assembly with side bearings into differential housing. Install bearing caps in correct orientation (reference marks from disassembly). Use side bearing adjuster tool or shims to position carrier. Mount dial indicator to measure ring gear backlash at several teeth around ring gear. Adjust side bearing position until backlash is within specification (typically 0.005-0.008 inches). Backlash must be consistent around entire ring gear within 0.002 inch variation. Tighten bearing cap bolts to specification per service manual.
11. 11

    Check gear contact pattern
    Apply thin coat of gear marking compound to 8-10 ring gear teeth in several locations. Rotate pinion through mesh with slight resistance (simulate load). Examine contact pattern on ring gear teeth. Pattern should be centered on tooth face for both drive and coast sides. Adjust pinion depth (requires disassembly) if pattern is too high or low on tooth. Adjust backlash if pattern is too far toward toe or heel. Repeat until proper pattern is achieved on both drive and coast sides.
12. 12

    Verify final preload and backlash
    With carrier properly installed and bearing caps torqued, verify pinion rotating torque is still within specification (should be slightly higher with carrier installed due to side bearing preload). Re-check ring gear backlash in multiple locations to confirm consistent measurement. Total rotating torque for pinion and carrier should be 20-35 in-lbs depending on bearing preload specifications.
13. 13

    Install differential cover
    Clean differential housing cover mating surface thoroughly. Install new gasket or apply RTV sealant per manufacturer specification (if using RTV, apply 1/8 inch bead and allow appropriate cure time). Install cover and tighten bolts in star pattern to specification per service manual. If using RTV, allow cure time before filling.
14. 14

    Fill differential with gear oil
    Fill differential with appropriate quantity of 75W-90 GL-5 gear oil through fill plug: 1.5 quarts for front differential or 2.0 quarts for rear differential. Fill until oil begins to seep from fill hole. Install fill plug and tighten to specification. Wipe away excess oil.

Reassembly

1. Reinstall driveshaft to differential yoke, aligning marks made during disassembly, and torque bolts to specification
2. Reinstall brake calipers and torque mounting bolts to specification
3. Reinstall wheels and torque lug nuts to specification in star pattern
4. Lower vehicle to ground
5. Reconnect 12V auxiliary battery and clear any diagnostic codes if present
6. Re-enable high voltage system per Rivian service procedures

Verification

• Test drive vehicle at low speed (under 30 mph) and listen for abnormal whine, howl, or grinding noises from differential
• Check for gear oil leaks around pinion seal and differential cover after test drive
• Monitor differential for unusual noise during initial 50-100 miles of break-in period - some light noise during break-in is normal
• Verify proper operation in both forward and reverse, confirming smooth engagement
• Re-check differential oil level after test drive and top off if necessary
• After 500 miles, consider changing gear oil to remove break-in debris, then again at 5,000 miles for optimal gear life

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